Yamaha Royal Star Tour Deluxe XVZ13CTW 2006 Owner'S Manual Download Page 60 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

EAU35193

Cleaning the air filter elements

The air filter elements should be
cleaned at the intervals specified in the
periodic maintenance and lubrication
chart. Clean the air filter elements more
frequently if you are riding in unusually
wet or dusty areas.

1. Remove cowlings A and B. (See

NOTE:

Continue as follows for each air filter el-
ement.

2. Remove the air filter case bolts.

3. Loosen the air filter case joint

clamp screw, and then pull the air
filter case off.

4. Remove the air filter case cover by

removing the screws.

5. Remove the air filter element by

removing the screws.

6. Lightly tap the air filter element to

remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.

1. Air filter case
2. Bolt

1. Air filter case joint clamp screw

1. Screw

1. Air filter element
2. Screw

1. Air filter element

U2C422E0.book Page 16 Wednesday, July 12, 2006 9:16 AM

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Summary of Contents for Royal Star Tour Deluxe XVZ13CTW 2006

Page 1: ...2C4 28199 22 XVZ13CTW OWNER S MANUAL ProCarManuals com ...

Page 2: ...U2C422E0 book Page 2 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 3: ...all advantages of your Royal Star Tour Deluxe The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safe guard yourself and others from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yama...

Page 4: ...ve any questions concerning this manual please consult your Yamaha dealer WARNING EWA10030 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE Product and specifications are subject to change without notice The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the m...

Page 5: ...6 by Yamaha Motor Co Ltd 1st edition July 2006 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan U2C422E0 book Page 2 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 6: ...or reducing fuel consumption 5 3 Engine break in 5 4 Parking 5 4 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 Owner s tool kit 6 1 Periodic maintenance and lubrication chart 6 2 Removing and installing cowlings and panels 6 6 Checking the spark plugs 6 9 Engine oil and oil filter cartridge 6 10 Final gear oil 6 13 Coolant 6 14 Cleaning the air filter elements 6 16 Adjusting the carburetors 6 17 Adjus...

Page 7: ...ke light bulb 6 33 Replacing the auxiliary light bulb 6 34 Supporting the motorcycle 6 35 Troubleshooting 6 35 Troubleshooting charts 6 36 MOTORCYCLE CARE AND STORAGE 7 1 Matte color caution 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 Motorcycle noise regulation for Australia 9 2 U2C422E0 book Page 2 Wednesday July 12 2006 9 16 AM ProCarManuals c...

Page 8: ...been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when ap proaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to oc cur Ride where other motorists can see...

Page 9: ... or goggles Wind in your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exha...

Page 10: ...e caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit ...

Page 11: ...e leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammabl...

Page 12: ...INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U2C422E0 book Page 5 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 13: ...olo leggete il manuale di istruzioni Lire le manuel du propriétaire avant d utiliser ce véhicule Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehículo lea el Manual del Propietario 5RU 21568 00 U2C422E0 book Page 6 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 14: ...l cock page 3 10 4 Fuel tank cap page 3 9 5 Battery page 6 29 6 Coolant reservoir page 6 14 7 Fuse box 2 page 6 30 8 Helmet holder page 3 14 9 Sidecase page 3 16 10 Tail brake light page 6 33 11 Rear turn signal light page 6 33 U2C422E0 book Page 1 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 15: ...er assembly air valve page 3 17 6 Rider seat page 3 12 7 Fuel tank page 3 9 8 Front fork air valve page 3 17 9 Windshield page 3 15 10 Headlight page 6 32 11 Front turn signal light page 6 33 12 Fuse box 1 page 6 30 13 Brake pedal page 3 8 14 Rider footrest 15 Passenger footrest U2C422E0 book Page 2 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 16: ...er page 3 7 2 Left handlebar switches page 3 6 3 Speedometer unit page 3 3 4 Main switch steering lock page 3 1 5 Right handlebar switches page 3 6 6 Throttle grip page 6 18 7 Brake lever page 3 8 U2C422E0 book Page 3 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 17: ...ked and all electrical systems are off The key can be re moved To lock the steering 1 Turn the handlebars all the way to the left or right 2 Push the key in from the OFF po sition and then turn it to LOCK while still pushing it 3 Remove the key To unlock the steering Push the key into the main switch and then turn it to OFF while still pushing it WARNING EWA10060 Never turn the key to OFF or LOCK ...

Page 18: ...arning light This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical cir cuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration...

Page 19: ... on when an electrical circuit monitoring the engine is defective When this occurs have a Yamaha dealer check the self diagno sis system The electrical circuit of the warning light can be checked by turning the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the electrical circuit EAU35151 Speedometer unit The speedometer unit is equipped wi...

Page 20: ...or at least two seconds To change the display back to the odometer and tripmeter modes push the SELECT button To set the clock 1 Push both the SELECT and RE SET buttons for at least two sec onds 2 When the hour digits start flashing push the RESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT ...

Page 21: ...ling speed as follows Press the RES ACC re sume accelerate side of the cruise control switch to increase the set speed or the SET DEC side to decrease the speed NOTE Pressing the cruise control switch once will change the speed in increments of 1 6 km h 1 mi h Holding the cruise control switch down will increase or de crease the speed continuously until the switch is released The traveling speed c...

Page 22: ... The traveling speed will return to the previously set speed Once the cruise control system is reactivated the SET indicator light will come on Push the CRUISE switch to the OFF position to completely cancel the cruise control system The ON indicator light will go off until the cruise control system is activated again NOTE Even if the CRUISE switch is in the ON position turning the main switch to ...

Page 23: ... cy such as when the vehicle overturns or when the throttle cable is stuck EAU12710 Start switch Push this switch to crank the engine with the starter CAUTION ECA10050 See page 5 1 for starting instruc tions prior to starting the engine EAU12780 Cruise control switches See page 3 5 for an explanation of the cruise control system EAU12820 Clutch lever The clutch lever is located at the left handleb...

Page 24: ...rcycle NOTE Use your toes or heel to shift up and your toes to shift down EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU12941 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal U2C422E0 bo...

Page 25: ...ck cover NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked WARNING EWA10130 Make sure that the fuel tank cap is properly installed before riding EAU13211 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown WARNING EWA10880 Do...

Page 26: ...rs use a gasoline of a different brand or premium unleaded fuel Use of un leaded fuel will extend spark plug life and reduce maintenance costs EAU13550 Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filter ing it The fuel cock lever positions are ex plained as follows and shown in the il lustrations OFF With the fuel cock lever in this position fuel will not flow...

Page 27: ...tion if you run out of fuel while riding When this occurs refuel as soon as possible and be sure to turn the fuel cock lever back to ON EAU13600 Starter choke knob Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the knob in direction a to turn on the starter choke Move the knob in direction b to turn off the starter choke 1 Pointed end position...

Page 28: ...aligned and then lock the steering with a suitable pad lock EAU35170 Rider seat To remove the rider seat Remove the bolts and then pull the rid er seat up To install the rider seat Insert the projection on the rear of the rider seat into the seat holder as shown place the seat in the original po sition and then tighten the bolts NOTE Make sure that the rider seat is properly secured before riding ...

Page 29: ...y pulling it to the rear as shown To install the backrest Place the backrest in the original posi tion then pull it backward until it stops and the levers snap locking it into place WARNING EWA12561 A loose backrest could cause an ac cident After installing the backrest check that both levers are fully locked into place 1 Backrest lever 1 Locked position U2C422E0 book Page 13 Wednesday July 12 200...

Page 30: ... hook the cable loops over the helmet holder 4 Place the helmet holder in the orig inal position and then remove the key WARNING EWA11040 Never ride with a helmet attached to a helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident To release the helmet from the hel met holder 1 Open the helmet holder remove the helmet holding cable from the helmet holder ...

Page 31: ...dshield in the original position as shown 2 Push the lever on each side of the windshield backward onto its fas tener to lock it into place WARNING EWA12541 A loose windshield could cause an accident Be sure the slot in each lever is securely fitted onto its fastener Be sure to pull both levers fully backward to lock the windshield into place 1 Windshield lever U2C422E0 book Page 15 Wednesday July...

Page 32: ...sidecases otherwise han dling could be affected Improp er loading poor tire or overall motorcycle conditions poor road surfaces or adverse weath er conditions may make it nec essary to further reduce the riding speed To open a sidecase 1 Insert the key into the lock turn it counterclockwise and then push it in 2 Fold the sidecase lid up To close a sidecase 1 Fold the sidecase lid down 2 Turn the k...

Page 33: ...ing rate and thereby soften the suspen sion decrease the air pressure by pushing each valve stem down CAUTION ECA10090 Never exceed the maximum air pres sure otherwise the front fork oil seals may become damaged 5 Securely install the air valve caps EAU14800 Adjusting the shock absorber assembly This shock absorber assembly is equipped with an air valve for adjusting the spring rate CAUTION ECA101...

Page 34: ... the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible lo...

Page 35: ...nd the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10250 If ...

Page 36: ...ine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not ...

Page 37: ...e accessory connected to the auxiliary DC connector should not be used with the engine turned off and the load must never exceed 5 A or 60 W otherwise the battery may discharge WARNING EWA12531 To prevent electrical shock or short circuiting make sure that the cap is installed when the auxiliary DC con nector is not being used 1 Auxiliary DC connector U2C422E0 book Page 21 Wednesday July 12 2006 9...

Page 38: ...herefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved WARNING EWA11150 If any item in the Pre operation check list is not working pr...

Page 39: ...age 6 14 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 22 6 23 6 24 Rear brake Check operation If soft or spongy have Yamaha dealer bleed hyd...

Page 40: ...read depth Check air pressure Correct if necessary 6 19 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 26 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 27 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 27 Chassis fasteners Make sure that all nuts b...

Page 41: ...e sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 19 Never ride with the sidestand down 1 Turn the fuel cock lever to ON 2 Turn the key to ON and make sure that the engine stop switch is set to 3 Shift the transmission into the neu tral position NOTE When the transmission is in the ...

Page 42: ...k the electrical circuit The engine trouble warning light should also come on when the key is turned to ON If the warning light does not come on when the key is turned to ON flashes or remains on after starting the engine have a Yamaha dealer check the elec trical circuit 6 After starting the engine move the starter choke back halfway CAUTION ECA11130 For maximum engine life always warm the engine...

Page 43: ...nning Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16800 Tips for reducing fuel con sumption Fuel consumption depends largely on your riding style Consider the following tips to reduce fuel consumption Turn the starter chok...

Page 44: ...0 1600 km 600 1000 mi Avoid prolonged operation above 1 2 throttle CAUTION ECA10331 After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car tridge or element replaced 1600 km 1000 mi and beyond The vehicle can now be operated nor mally CAUTION ECA10270 If any engine trouble should occur during the engine break in period immediately have a Yamaha d...

Page 45: ...iar with mainte nance work have a Yamaha dealer do it for you EAU35870 Owner s tool kit The owner s tool kit is located inside the right sidecase See page 3 16 The service information included in this manual and the tools provided in the owner s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may b...

Page 46: ...METER READING 1000 km ANNUAL CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust Every 40000 km 5 Air filter elements Clean Replace 6 Clutch Check operation fluid level and vehicle for fluid leakage 7 Front brake Check operation fluid level and vehicle for flu...

Page 47: ...ithium soap based grease Every 50000 km 15 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 16 Sidestand Check operation Lubricate 17 Sidestand switch Check operation 18 Front fork Check operation and for oil leakage 19 Shock absorber assem bly Check operation and shock absorber for oil leakage 20 Rear suspension relay arm and connecting arm pivoting points Check o...

Page 48: ...kage Change Every 3 years 25 Final gear oil Check oil level and vehicle for oil leakage Change 26 Front and rear brake switches Check operation 27 Moving parts and ca bles Lubricate 28 Throttle grip housing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 29 Mufflers and exhaust pipes Check the screw clamps for l...

Page 49: ...mponents of the brake master cylinders and calipers as well as clutch master and release cylinders and change the brake and clutch fluids Replace the brake and clutch hoses every four years and if cracked or damaged U2C422E0 book Page 5 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 50: ...moved and installed EAU35841 Cowling A To remove the cowling 1 Remove the bolts 2 Remove the quick fastener screw by turning it 1 4 turn counterclock wise and then take the cowling off To install the cowling Place the cowling in the original posi tion and then install the quick fastener screw and the bolts 1 Cowling A 2 Panel A 1 Cowling B 2 Panel B 3 Panel C 1 Cowling A 2 Bolt 3 Quick fastener sc...

Page 51: ... install the cowling 1 Place the cowling in the original position and then install the bolts NOTE Make sure that the projection fits into the grommet 2 Install cowling A EAU35860 Panels A and B To remove one of the panels Remove the bolt and then pull the pan el off as shown 1 Grommet 2 Projection 3 Cowling A 1 Cowling B 2 Bolt 1 Bolt 1 Panel A 2 Bolt U2C422E0 book Page 7 Wednesday July 12 2006 9 ...

Page 52: ...emove the left passenger foot rest by removing the bolts 3 Remove the screw and then pull the panel off as shown To install the panel 1 Place the panel in the original posi tion and then install the screw 2 Install the passenger footrest by installing the bolts 3 Install panel B 1 Panel B 2 Bolt 1 Panel C 2 Screw 3 Bolt U2C422E0 book Page 8 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 53: ... electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine could be oper ating improperly Do not attempt to diagnose such problems yourself In stead have a Yamaha dealer check the vehicle 3 Check each spark pl...

Page 54: ... oil level 1 Place the vehicle on a level sur face and hold it in an upright posi tion NOTE Make sure that the vehicle is positioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window lo...

Page 55: ...e with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge NOTE Make sure that the O ring is properly seated 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 1 Engine oil filler cap 1 Engine oil drain bolt 1 Oil...

Page 56: ... it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient CAUTION ECA10400 If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 10 Turn the engine off and then check the oil ...

Page 57: ...inal gear case NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the...

Page 58: ... be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 3 Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum level marks 4 If the coolant is at or below the minimum level mark remo...

Page 59: ...olant will be reduced WARNING EWA10380 Never attempt to remove the radiator cap when the engine is hot 5 Install the panel NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 36 for further instructions EAU33030 Changing the coolant WARNING EWA10380 Never attempt to remove the radiator cap when the engin...

Page 60: ...ve the air filter case bolts 3 Loosen the air filter case joint clamp screw and then pull the air filter case off 4 Remove the air filter case cover by removing the screws 5 Remove the air filter element by removing the screws 6 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damag...

Page 61: ...he air filter case bolts 11 Install the cowlings NOTE Make sure that the carburetor air vent hose is routed as shown EAU21290 Adjusting the carburetors The carburetors are important parts of the engine and require very sophisticat ed adjustment Therefore most carbu retor adjustments should be left to a Yamaha dealer who has the neces sary professional knowledge and expe rience The adjustment descr...

Page 62: ...necessary adjust it to spec ification by turning the throttle stop screw To increase the engine idling speed turn the screw in di rection a To decrease the en gine idling speed turn the screw in direction b NOTE If the specified idling speed cannot be obtained as described above have a Yamaha dealer make the adjustment EAU21381 Checking the throttle cable free play The throttle cable free play sho...

Page 63: ...he ambient temperature The tire air pressure must be ad justed in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model WARNING EWA11020 Because loading has an enormous impact on the handling braking performance and safety characteris tics of your motorcycle you should keep the following precautions in mind NEVER OVERLOAD THE M...

Page 64: ...acked con tact a Yamaha dealer immediately and have the tire replaced NOTE These limits may be different by regula tion from country to country If so con form to the limits specified by the regulations of your own country WARNING EWA10470 Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the vehi cle with excessively worn tires decreases riding stability and can l...

Page 65: ... A deformed or cracked wheel must be replaced The wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics After rep...

Page 66: ... brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make sure that the brake is worki...

Page 67: ...s provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator grooves If a brake pad has worn to the point that the wear indicator grooves have almost disap peared have a Yamaha dealer replace the brake pads as a set EAU22470 Rear brake pads Each rear brake pad is provided with a wear...

Page 68: ...top of each reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance Be careful that water does not en ter the brake or clutch fluid reser voir when r...

Page 69: ...aged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years EAU23100 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it...

Page 70: ...be lubricated at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U2C422E0 book Page 26 Wednesday July 12 2006 9 16 AM ProCarMa...

Page 71: ...t fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart To check the condition WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur ...

Page 72: ...checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground WARNING EWA10750 Securely support the vehicle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer...

Page 73: ...damage the battery WARNING EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL Drink large quan tities of water or milk and im mediately call a...

Page 74: ...nd fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals CAUTION ECA10630 Always keep the battery charged Storing a discharged battery can cause permanent battery damage To charge a sealed type MF battery a special constant volt age battery charger is required Using a conve...

Page 75: ...y a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 1 Cruise control fuse 2 Carburetor heater fuse 3 Auxiliary DC connector fuse 4 Spare fuse 1 Backup fuse for odometer and clock 2 Radiator fan fuse 3 Headlight fuse 4 Signaling system fuse 5 Ignition fuse 6 Spare fuse Specified fuses Main fuse 30 0 A Cruise control fuse 10 0 A Carburetor hea...

Page 76: ...tz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 3 Unhook the headlight bulb holder and then remove the defective bulb 1 Screw 1 Headlight coupler 2 Headlight bulb cover 1 Headlight bulb holder U2C422E0 book Page 32 Wednesday July 12 2006 9 16 AM ProCarManual...

Page 77: ...glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary EAU24281 Replacing a t...

Page 78: ...urns out re place it as follows 1 Remove the headlight unit by re moving the screws 2 Remove the socket together with the bulb by pushing it in and turn ing it counterclockwise 3 Remove the defective bulb by pushing it in and turning it counter clockwise 4 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 5 Install the socket together with the bulb by pushing ...

Page 79: ...rcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can caus...

Page 80: ... Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the electric starter 4 Battery The engine...

Page 81: ...down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check the cooling system for leakage Hav...

Page 82: ...lets with plas tic bags after the engine has cooled down 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and de greas...

Page 83: ...et cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle wi...

Page 84: ...re product Avoid using abrasive polishing compounds as they will wear away the paint NOTE Consult a Yamaha dealer for advice on what products to use EAU26250 Storage Short term Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover CAUTION ECA10810 Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still...

Page 85: ...plugs and then install the spark plugs and the spark plug caps WARNING EWA10950 To prevent damage or injury from sparking make sure to ground the spark plug electrodes while turning the engine over 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 Check and if necessary correct the tire air pressure and then lift the motorcyc...

Page 86: ... 91 US qt 3 26 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil Quantity 0 20 L 0 21 US qt 0 18 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 35 L 0 37 US qt 0 31 Imp qt Radiator capacity including all routes 3 50 L 3 70 US qt 3 08 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Unleaded gasoline only Fuel tank capacity 20 0 L 5 28 ...

Page 87: ... kgf cm Loading condition 90 201 kg 198 443 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Front wheel Wheel type Cast wheel Rim size 16M C x MT3 50 Rear wheel Wheel type Cast wheel Rim size 15M C x MT4 00 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Recommended fluid DO...

Page 88: ...or light LED Oil level warning light LED Turn signal indicator light LED Coolant temperature warning light LED Engine trouble warning light LED Overdrive indicator light LED Cruise control SET indicator light LED Cruise control ON indicator light LED Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 15 0 A Ignition fuse 10 0 A Radiator fan fuse 10 0 A Carburetor heater fuse 15 0 A...

Page 89: ...n number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a new key EAU26400 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be use...

Page 90: ...IBITED Owners are warned that the law may prohibit a The removal or rendering inopera tive by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the pur pose of noise control prior to its sale or delivery to the ultimate pur chaser or while it is in use and b The use of the vehicle after such device or el...

Page 91: ...or reducing 5 3 Fuel tank cap 3 9 Fuses replacing 6 30 H Handlebar switches 3 6 Headlight bulb replacing 6 32 Helmet holder 3 14 High beam indicator light 3 2 Horn switch 3 7 I Identification numbers 9 1 Ignition circuit cut off system 3 19 Indicator and warning lights 3 2 K Key identification number 9 1 L Labels location of 1 5 M Main switch steering lock 3 1 Matte color caution 7 1 Model label 9...

Page 92: ...ng 6 35 Troubleshooting charts 6 36 Turn signal indicator light 3 2 Turn signal light bulb or tail brake light bulb replacing 6 33 Turn signal switch 3 7 V Valve clearance 6 19 Vehicle identification number 9 1 W Wheel bearings checking 6 29 Wheels 6 21 Windshield 3 15 U2C422E0 book Page 2 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 93: ...U2C422E0 book Page 3 Wednesday July 12 2006 9 16 AM ProCarManuals com ...

Page 94: ...PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD PRINTED IN JAPAN 2006 08 0 3 1 CR E ProCarManuals com ...

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